EP1213728A2 - Dispositif de limitation de courant - Google Patents

Dispositif de limitation de courant Download PDF

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Publication number
EP1213728A2
EP1213728A2 EP01128172A EP01128172A EP1213728A2 EP 1213728 A2 EP1213728 A2 EP 1213728A2 EP 01128172 A EP01128172 A EP 01128172A EP 01128172 A EP01128172 A EP 01128172A EP 1213728 A2 EP1213728 A2 EP 1213728A2
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EP
European Patent Office
Prior art keywords
current
limiting
limiting device
electrodes
insulator
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Withdrawn
Application number
EP01128172A
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German (de)
English (en)
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EP1213728A3 (fr
Inventor
William K. Hanna
Jeffery A. Miller
John J. Shea
Stephen Albert Mrenna
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Eaton Corp
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Eaton Corp
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Filing date
Publication date
Application filed by Eaton Corp filed Critical Eaton Corp
Publication of EP1213728A2 publication Critical patent/EP1213728A2/fr
Publication of EP1213728A3 publication Critical patent/EP1213728A3/fr
Withdrawn legal-status Critical Current

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    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01C—RESISTORS
    • H01C7/00—Non-adjustable resistors formed as one or more layers or coatings; Non-adjustable resistors made from powdered conducting material or powdered semi-conducting material with or without insulating material
    • H01C7/13—Non-adjustable resistors formed as one or more layers or coatings; Non-adjustable resistors made from powdered conducting material or powdered semi-conducting material with or without insulating material current responsive
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01C—RESISTORS
    • H01C7/00—Non-adjustable resistors formed as one or more layers or coatings; Non-adjustable resistors made from powdered conducting material or powdered semi-conducting material with or without insulating material
    • H01C7/02—Non-adjustable resistors formed as one or more layers or coatings; Non-adjustable resistors made from powdered conducting material or powdered semi-conducting material with or without insulating material having positive temperature coefficient
    • H01C7/028—Non-adjustable resistors formed as one or more layers or coatings; Non-adjustable resistors made from powdered conducting material or powdered semi-conducting material with or without insulating material having positive temperature coefficient consisting of organic substances

Definitions

  • This invention pertains generally to current-limiting devices and, more particularly, to current-limiting devices including a current-limiting material which is engaged by electrodes.
  • the current-limiting polymer compositions generally include conductive particles, such as carbon black, graphite or metal particles, dispersed in a polymer matrix, such as a thermoplastic polymer, elastomeric polymer or thermosetting polymer.
  • PTC behavior in a current-limiting polymer composition is characterized by the material undergoing a sharp increase in resistivity as its temperature rises above a particular value known as the switching temperature. Materials exhibiting PTC behavior are useful in a number of applications such as, for example, electrical circuit protection devices, in which the current passing through a circuit is controlled by the temperature of a PTC element forming part of that circuit.
  • Electrical circuit protection devices comprising current-limiting polymer compositions typically include a current-limiting polymer device having two electrodes embedded in a current-limiting polymer composition.
  • the circuit protection devices When connected to a circuit, the circuit protection devices have a relatively low resistance under normal operating conditions of the circuit, but are tripped, that is, converted into a high resistance state, when a fault condition or persistent overcurrent condition occurs. Under such conditions, when the circuit protection device is tripped, the current passing through the PTC element causes it to resistively self-heat to its switching temperature, T s , at which a rapid increase in its resistance takes place.
  • the residual current which flows through the current-limiting device, allows a series circuit breaker to absorb any stored residual energy (e.g., the majority of such energy is absorbed by the circuit breaker arc chamber during the switching transient and during recovery/reclosing to reestablish the power distribution system voltage) in the power distribution system.
  • an external current-limiting device engages the load-side terminals of the circuit breaker.
  • a conductive polymer of the current-limiting device is coupled in series with the mechanical circuit breaker separable contacts, in order to limit fault current as those contacts open.
  • Previous materials used for current-limiting applications in conjunction with low voltage circuit breakers generally consisted of a very brittle blend of conductive filler (i.e., carbon black) and a thermoplastic binder with two spring-loaded metal plates employed as electrodes. These electrodes serve to allow current to flow through the current-limiting material. In this arrangement, approximately 80% of the total device resistance in the low resistance state resulted from contact resistance, while only about 20% resulted from bulk material resistance.
  • the present invention provides improvements in the operation of current-limiting devices by providing a current-limiting device which compresses a first insulator, a first electrode, a current-limiting material, a second electrode and a second insulator with first and second clips.
  • a current-limiting device comprises a current-limiting material having first and second sides; first and second electrodes structured for carrying current through the current-limiting material, each of the electrodes having first and second sides, with the second side of the first electrode engaging the first side of the current-limiting material, and with the first side of the second electrode engaging the second side of the current-limiting material; first and second insulators, each of the insulators having first and second sides, with the second side of the first insulator engaging the first side of the first electrode, and with the first side of the second insulator engaging the second side of the second electrode; and first and second clips engaging different portions of the first side of the first insulator and the second side of the second insulator, and compressing the first insulator, the first electrode, the current-limiting material, the second electrode and the second insulator.
  • each of the first and second clips includes first and second arms, with the first arm of the first clip engaging a first portion of the first side of the first insulator and the second arm of the first clip engaging a corresponding first portion of the second side of the second insulator, and with the first arm of the second clip engaging a second portion of the first side of the first insulator and the second arm of the second clip engaging a corresponding second portion of the second side of the second insulator.
  • the first and second electrodes are solely electrically connected by the current-limiting material.
  • the current-limiting material and a shunt electrically connect the first and second electrodes.
  • the shunt may be a conductor which is electrically connected to the first and second electrodes.
  • the conductor may include a pair of ends each of which is cinched to one of the first and second electrodes.
  • the conductor may include one or more serpentine portions. A first serpentine portion may be parallel to the first arms of the first and second clips, and a second serpentine portion may be parallel to the second arms of the first and second clips.
  • a low voltage current-limiting resistance device 10 for providing electrical circuit protection for electrical apparatus.
  • a suitable metal or plastic case 12 shown split into two parts, are metal bifold springs 14, resting on polyethylene terephthalate (Mylar) sheets 16, and supporting copper electrodes 18 on each side of a thin polymeric sheet of conductive current-limiting polymer composition 20, which may exhibit PTC behavior.
  • Mylar polyethylene terephthalate
  • the springs 14, the electrodes 18 and vents 22 are further detailed.
  • a wide range of other type springs such as, for example, wave or compression springs, may be used to provide the contacting relationship between the electrodes 18 and the current-limiting polymer composition 20.
  • Figure 3 shows two plots 24 (with a shunt) and 26 (without a shunt) of let-through current versus time for two current-limiting devices which do (not shown) and do not ( e.g., the device 10 of Figures 1 and 2) employ a parallel electrical shunt electrically connected between the electrodes to protect the current-limiting polymer (e.g., polyethylene).
  • the sharp drop in current at point 28 of plot 26 is a result of a crowbar circuit (not shown).
  • a current-limiting device 30 is shown. Both electrodes 32,34 of the device 30 are pressed by different forces 36,37, in order to make suitable electrical contact with a suitable current-limiting material 38.
  • the magnitude and the stiffness of the forces 36,37 i.e., the spring rate, k, in pounds per inch
  • the electrodes 32,34 are structured for carrying current through the current-limiting material 38, with the electrode 32 electrically engaging a first portion 40 of the material 38, and the electrode 34 electrically engaging a second portion 42 of the material 38.
  • the exemplary forces 36 and 37 (one of which might be zero) provide a non-uniform pressure distribution between one or both of the electrodes 32,34 and the current-limiting material 38.
  • the electrodes 32,34 are solely electrically connected by the current-limiting material 38.
  • the electrodes 32,34 are made of any suitably conductive metal, such as, for example, copper, or alloy or any such suitably conductive metal or alloy, which is plated in order to reduce or minimize oxidation.
  • Suitable plating materials for the electrodes 32,34 include, for example, silver, nickel, gold, platinum, and other types of plating metals, which preferably maintain high conductivity over the life of the current-limiting device 30.
  • thermoset e.g., carbon black filled thermosetting resins
  • thermoplastic type current-limiting polymers e.g., polyethylene terephthalate
  • elastomeric polymers e.g., polyethylene terephthalate
  • the current limiting polymer is a mixture of readibly commercially available materials, such as epoxy resins, that are flexible and moldable, can be finished, are not brittle upon cure, and that are cuttable or punchable so they can be inexpensively volume-produced in long sheet form.
  • Such an epoxy based current-limiting material can be cast as a thin film (e.g., about 40 cm x 80 cm and between 0.05 cm and 0.5 cm, usually 0.13 cm (0.05 inch) thick), and then cut into smaller component pieces, for example, 6.1 cm x 4.0 cm x 0.12 cm thick ( i.e. , about 2.4 inch x 1.6 inch x 0.05 inch) without fracturing.
  • Such electrically conducting material exhibits superior flexibility and punchability, electrical conductivity characteristics, and low let-through ( i.e ., the measure of effectiveness of the current limiter in reducing current and the duration of the current, typically less than 10 x 10 3 A 2 -s), for use in a current limiting polymer device.
  • Such electrically conducting material consists essentially of the cured reaction product of: a resin component comprising a mixture of: 100 parts by weight of a short chain aliphatic diepoxide resin and 0 to 15 parts by weight of a bisphenol A epoxy resin, 80 to 150 parts by weight of conductive filler, and curing agent.
  • a resin component comprising a mixture of: 100 parts by weight of a short chain aliphatic diepoxide resin and 0 to 15 parts by weight of a bisphenol A epoxy resin, 80 to 150 parts by weight of conductive filler, and curing agent.
  • the aliphatic diepoxide is the diglycidyl ether of an alkylene glycol
  • the bisphenol A epoxy resin is present in the range of 1 to 10 parts by weight to add strength to the material
  • the curing agent is a borontrifluoride-amine complex.
  • no epoxidized bisphenol A epoxy is present a minor amount, about 2 to 20 parts by weight, of an epoxidized polybut
  • an external shunt is no longer needed for the current-limiting device 30.
  • a nominal maximum let-through value e.g. , approximately 500 A
  • the fault current is limited and the magnetic energy in the electrical circuit may, thus, be suitably dissipated.
  • the exemplary current-limiting device 30 does not require a shunting resistance, there is a savings in cost, the package volume is reduced, and efficiency is increased.
  • an ideal switch transitions to a resistance that rapidly drives the fault current to zero, thereby causing a high transient voltage to appear across the current-limiting material and, thus, causing the stored magnetic system energy to destroy that current-limiting material.
  • the residual current in the current-limiting material 38 is controlled, without the need for a commutating shunt.
  • the ability to continue to conduct current through the current-limiting material 30 depends upon the type of current-limiting material as well as the dynamics of the electrodes 32,34.
  • springs e.g ., compression springs
  • a relatively rigid structure e.g., a wave spring; silicone rubber
  • the electrodes 32,34 are not allowed to lift-off the surface of the current-limiting material 38, but are held rather firmly onto, but not embedded into ( see, e.g ., commonly assigned Application Serial No. ___/___,___ (Attorney Docket No. 99-PDC-137)), the current-limiting material 38 during the entire switching transient.
  • one possible goal is to maintain a relatively low residual current and to minimize re-conduction. This allows for inductive energy to be safely dissipated.
  • re-conduction per se does not cause damage to the current-limiting material 38, but only causes a minimal increase in let-through current.
  • This spring rate preferably produces a minimum let-through current value and does not result in re-conduction.
  • the gas pressure produced from the vaporization of the interfaces between the electrodes 32,34 and the current-limiting material 38 of Figure 4 during the switching transient is also important in obtaining the desired residual current.
  • the amount of force applied to the case e.g ., the case 12 of Figure 1
  • Sealing the case 12 would, however, result in a greater force to such case and case rupture.
  • the residual current is reliably controlled. Description Spring Rate, k (lbs./in.) Residual Current, I R (A) Compression 102 0 BiFold 333 475 Wave Washer 714 750 Wave Spring 5000 1600 Silicone Rubber 6666 1904
  • the exemplary current-limiting devices disclosed herein employ mechanisms that provide a non-uniform pressure distribution and include a suitable spring having a predetermined spring rate, such as the exemplary spring rates of Table 1.
  • the predetermined spring rate is about 100 to about 7000 pounds per inch.
  • the predetermined spring rate is about 100 to about 700 pounds per inch, with a spring rate of about 300 pounds per inch providing minimum let-through current value without re-conduction.
  • the selected spring rate is important in determining the resulting switching properties of the current-limiting devices. For example, spring rate determines the residual current, I R , which has a large affect on the let-through energy.
  • the resulting total pressure would be 111 PSI (i.e., 333 lbs./in. x 0.1 in./0.3 in. 2 ).
  • the mechanical pressure distribution on the surface of the current-limiting material 38 is also important in determining the peak current and the device resistance.
  • the pressure is relatively low (e.g., typically less than 20 PSI). This relatively low pressure typically produces high device resistance and increases the switching current.
  • the current-limiting material 38, the electrodes 32,34, and the forces 36,37 of Figure 4 are cooperatively structured for: (1) limiting a maximum residual let-through current (i.e ., current after switching) to about 475 amperes to about 750 amperes (see Figure 8); (2) minimizing or eliminating re-conduction through the current-limiting material 38 ( Figures 6-8); and (3) through appropriate selection (as shown in Figure 9), providing a predetermined residual let-through current through the current-limiting material 38, and a predetermined spring rate for the forces 36,37.
  • a maximum residual let-through current i.e ., current after switching
  • Figures 6-8 minimizing or eliminating re-conduction through the current-limiting material 38
  • Figure 9 through appropriate selection
  • the differential pressure is increased ( e.g., to greater than 40 PSI) by non-uniformly loading the electrodes 32,34 ( e.g ., by employing the loading as shown in Figures 10-12) having the desired spring rate, then the desired low device resistance, reduced switching current, and low residual current are provided without any re-conduction.
  • This is at the expense of increases in the let-through current, due to the relatively higher spring force needed to obtain the desired package resistance over the smaller area of contact, and increases in erosion of the current-limiting material 38 at the areas of relatively higher pressure.
  • FIG. 10-12 another current-limiting device 50 is shown including two exemplary copper electrodes 52,54, two exemplary "money-clip" springs 56,58, a suitable current-limiting polymer material 60, and suitable insulators in the form of the exemplary red glass polyester 62,64, respectively.
  • the current-limiting material 60 has a first side 66 and a second side 68 ( Figure 10).
  • the first and second electrodes 52,54 are structured for carrying current through the current-limiting material 60.
  • Each of the electrodes 52,54 has a first side 70 and a second side 72.
  • the second side 72 of the first electrode 52 engages the first side 66 of the current-limiting material 60.
  • the first side 70 of the second electrode 54 engages the second side 68 of the current-limiting material 60.
  • Each of the insulators 62,64 has a first side 74 and a second side 76.
  • the second side 76 of the first insulator 62 engages the first side 70 of the first electrode 52.
  • the first side 74 of the second insulator 64 engages the second side 72 of the second electrode 54.
  • the first and second clips 56,58 engage different portions of the first side 74 of the first insulator 62 and the second side 76 of the second insulator 64, in order to compress the first insulator 62, the first electrode 52, the current-limiting material 60, the second electrode 54 and the second insulator 64.
  • the first and second clips 56,58 have opposing clip spring clamping arm members 78,80.
  • the first arm 78 of the first clip 56 engages a first portion 82 of the first side 74 of the first insulator 62 and the second arm 80 of the first clip 56 engages a corresponding first portion 82 of the second side 76 of the second insulator 64.
  • the first arm 78 of the second clip 58 engages a second portion 84 of the first side 74 of the first insulator 62 and the second arm 80 of the second clip 58 engages a corresponding second portion 84 of the second side 76 of the second insulator 64.
  • the first and second arms 78,80 of the clips 56,58 have predetermined spring rates of about 100 lbs./in. to 800 lbs./in. with a preferred range between about 150 lbs./in. to 400 lbs./in.
  • the first side 74 of the first insulator 62 and the second side 76 of the second insulator 64 preferably include a third portion 86 which is not engaged by the clips 56,58, in order to provide a non-uniform pressure distribution between the first insulator 62, the first electrode 52, the current-limiting material 60, the second electrode 54 and the second insulator 64.
  • the third portion 86 is not required and the force distribution suitably varies along the length of the arms 78,80.
  • the exemplary electrodes 52,54 are solely electrically connected by the current-limiting material 60. External electrical connections to the electrodes 52,54 are preferably provided by exemplary electrical conductors 88,90 (shown in Figure 11), respectively, which are suitably electrically connected ( e.g. , welded, brazed) to the electrodes 52,54 or which, alternatively, are made part of such electrodes.
  • FIG. 13-16 another current-limiting device 100 is shown including two exemplary copper electrodes 102,104, two exemplary "money-clip" springs 106,108, a suitable current-limiting polymer material 110, suitable insulators in the form of the exemplary red glass polyester 112,114, respectively, and a shunt 116 between the electrodes 102,104.
  • the current-limiting device 100 is similar to the current-limiting device 50 of Figures 10-12, except that the shunt 116 is employed.
  • the electrodes 102,104 are electrically connected by the current-limiting material 110 and by the shunt 116.
  • the shunt 116 is a conductor which is electrically connected to the electrodes 102,104.
  • the shunt 116 may be made from iron wire of about 0.1 in. diameter. Depending on the desired resistance and energy absorption, the wire diameter, length and material may be suitably selected.
  • each of the ends 118,120 (as shown in Figure 13) of the shunt 116 is cinched to a corresponding one of the electrodes 102,104.
  • the shunt 116 preferably includes one or more serpentine portions 122 (as best shown in Figure 14) which are parallel to the arms 124,126 of the clips 106,108.
  • the serpentine portion 122 is proximate the arms 124 of the clips 106,108 (as shown in Figures 14 and 15), and the serpentine portion 128 is proximate the arms 126 of the clips 106,108.
  • the serpentine portion 122 is parallel to the arms 124, and the serpentine portion 128 is parallel to the arms 126.
  • a wide variety of different types of springs may be employed to provide the desired force and spring rate in a given dimension.
  • Figure 17 shows a conductive polymer current-limiting resistance device 150, including a plurality ( e.g., three) of the conductive polymer current-limiting devices 50 of Figures 10-12, which devices are connected electrically in series with three power lines between a three-phase load 152 and a three-phase circuit breaker 154, with a three-phase power source shown as 156.
  • the current-limiting polymer material 60 ( Figure 10) in one of the devices 50 undergoes a sharp increase in resistivity due to a large influx of current in one of the phases of the power circuit, its temperature rises above its switching temperature, T s , at which a rapid increase in its resistance takes place to transform it to a high resistance state.
  • the current-limiting devices 50 and 100 of respective Figures 10-12 and 13-16 are relatively easy to manufacture, and readily facilitate the venting of gas from those devices.
  • the exemplary current-limiting device 50 of Figures 10-12 allows for quick and easy assembly/disassembly compared to known prior devices.
  • the relatively low spring force increases the life of the device and lowers the assembly costs.
  • the device 50 has a relatively compact design and employs a thermoset polymer (long life) compared to known prior art thermoplastic devices.
  • the device 50 has a low switching current (i.e., about 4.5 kA) compared to known prior devices (about 6-8 kA).
  • the current-limiting device 100 of Figures 13-16 provides a relatively longer life (less polymer erosion), and an increased safety factor (the shunt is a backup in case polymer resistance gets too high). Furthermore, the device 100 can absorb relatively larger inductive faults.

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  • Engineering & Computer Science (AREA)
  • Microelectronics & Electronic Packaging (AREA)
  • Physics & Mathematics (AREA)
  • Electromagnetism (AREA)
  • Ceramic Engineering (AREA)
  • Emergency Protection Circuit Devices (AREA)
EP01128172A 2000-11-27 2001-11-27 Dispositif de limitation de courant Withdrawn EP1213728A3 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US72336400A 2000-11-27 2000-11-27
US723364 2000-11-27

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EP1213728A2 true EP1213728A2 (fr) 2002-06-12
EP1213728A3 EP1213728A3 (fr) 2005-10-26

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Citations (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4331861A (en) * 1979-09-28 1982-05-25 Siemens Aktiengesellschaft Positive temperature coefficient (PTC) resistor heating device
US4698614A (en) * 1986-04-04 1987-10-06 Emerson Electric Co. PTC thermal protector
EP0487920A1 (fr) * 1990-10-30 1992-06-03 Asea Brown Boveri Ab Composant à coefficient de température positif
US5565826A (en) * 1992-11-02 1996-10-15 Karlstr+E,Uml O+Ee M; Per Olof Overload protective system
US5644283A (en) * 1992-08-26 1997-07-01 Siemens Aktiengesellschaft Variable high-current resistor, especially for use as protective element in power switching applications & circuit making use of high-current resistor
EP0853322A1 (fr) * 1996-12-19 1998-07-15 Eaton Corporation Interface électrique à faible résistance dans polymères limiteurs de courant réalisée par traitement au plasma

Patent Citations (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4331861A (en) * 1979-09-28 1982-05-25 Siemens Aktiengesellschaft Positive temperature coefficient (PTC) resistor heating device
US4698614A (en) * 1986-04-04 1987-10-06 Emerson Electric Co. PTC thermal protector
EP0487920A1 (fr) * 1990-10-30 1992-06-03 Asea Brown Boveri Ab Composant à coefficient de température positif
US5644283A (en) * 1992-08-26 1997-07-01 Siemens Aktiengesellschaft Variable high-current resistor, especially for use as protective element in power switching applications & circuit making use of high-current resistor
US5565826A (en) * 1992-11-02 1996-10-15 Karlstr+E,Uml O+Ee M; Per Olof Overload protective system
EP0853322A1 (fr) * 1996-12-19 1998-07-15 Eaton Corporation Interface électrique à faible résistance dans polymères limiteurs de courant réalisée par traitement au plasma

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Publication number Publication date
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